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Lattner Boiler Company Scotch Marine Steam & Hot Water Boilers Lattner Boiler Company Scotch Marine Steam & Hot Water Boilers INSTRUCTION MANUAL December 2005 Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 T: (800) 345-1527 F: (319) 366-0770 E: [email protected] www.lattnerboiler.com LATTNER BOILER COMPANY Scotch Marine Boiler Operations Manual _______________________________________________________________________________________________________________________________________ Index Section I: General Description Page 3 1. Boiler Design ………………………………………………………………..………………………………….3 2. Boiler Connections ………………………………………………………………..………………………………….4 3. Boiler Trim ………………………………………………………………..………………………………….4 4. Fuel Burning System ………………………………………………………………..………………………………….5 5. Fuel/Air Control ………………………………………………………………..………………………………….5 6. Gas/Fuel Train ………………………………………………………………..………………………………….6 7. Control Panel ………………………………………………………………..………………………………….6 8. Factory Tests ………………………………………………………………..………………………………….7 9. Nameplates & Stamping ………………………………………………………………..………………………………….7 10. Guarantees ………………………………………………………………..………………………………….7 Section II: Installation Page 8 1. Unloading ………………………………………………………………..………………………………….8 2. Rigging ………………………………………………………………..………………………………….8 3. Placement of Boiler ………………………………………………………………..………………………………….8 4. Combustion Air ………………………………………………………………..………………………………….8 5. Stack ………………………………………………………………..………………………………….9 6. Steam Outlet ………………………………………………………………..………………………………….9 7. Blowdown Piping …………………………………………………………….…………………………………...10 8. Safety Valve …………………………………………………………….…………………………………...11 9. Gas/Fuel Train Piping …………………………………………………………….…………………………………...11 10. Boiler Feed Systems …………………………………………………………….…………………………………...12 11. Electrical Connections …………………………………………………………….…………………………………...13 12. Before Firing the Boiler …………………………………………………………….…………………………………...13 13. Pressuretrols: Controller & Limit …………………………………………………………….…………………………………...14 14. Firing the Boiler …………………………………………………………….…………………………………...15 15. Boil Out Recommendations for New Boilers …………………………………………………………….…………………………………...16 16. Standard Maintenance Items …………………………………………………………….…………………………………...16 17. Water Quality Limits for Lattner Boilers …………………………………………………………….…………………………………...17 Section III: Boiler Care & Maintenance Page 18 1. Daily Procedures …………………………………………………………….…………………………………...18 2. Weekly Procedures …………………………………………………………….…………………………………...18 3. Monthly Procedures …………………………………………………………….…………………………………...18 4. Annual Procedures …………………………………………………………….…………………………………...19 5. Care of Idle Boilers …………………………………………………………….…………………………………...19 6. Care & Service of Boiler Tubes …………………………………………………………….…………………………………...19 7. Boiler Tube Replacement …………………………………………………………….…………………………………...20 8. Handhole Plate Removal & Replacement …………………………………………………………….…………………………………...21 9. Sight Glass Removal & Installation …………………………………………………………….…………………………………...22 10. McDonnell Miller Servicing …………………………………………………………….…………………………………...23 11. Warrick Relay Replacement …………………………………………………………….…………………………………...24 12. Auxiliary Low Water Cut-Off Probe Cleaning …………………………………………………………….…………………………………...24 Section IV: Troubleshooting Page 25 1. Normal Operation …………………………………………………………….…………………………………...25 2. Basic Service Tools …………………………………………………………….…………………………………...25 3. Before You Begin …………………………………………………………….…………………………………...25 4. Troubleshooting …………………………………………………………….…………………………………...26 _______________________________________________________________________________________________________________________________________ Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com LATTNER BOILER COMPANY Page 3 Scotch Marine Boiler Operations Manual _______________________________________________________________________________________________________________________________________ Section I: General Description WARNING: All installation procedures must be followed completely by a competent installer familiar with boilers and boiler accessories. CAUTION: Read and follow all instructions before installing any boiler equipment. All cover plates, enclosures and guards must be maintained and in place at all times, except during maintenance and servicing. 1. Boiler Design Lattner horizontal firetube boilers are designed as three pass scotch marine dry back boilers with integral furnaces and convective heat transfer firetubes. The furnace and heat transfer tubes are completely submerged beneath the normal operating water level. The total heating surface is based on 5 square feet per boiler horsepower (output). All Lattner firetube boilers are built in accordance to the appropriate ASME Code for low pressure steam, high pressure steam, low pressure hot water, or high pressure hot water. 1.1. Gas Flow The tube design of Lattner firetube boilers provides three pass longitudinal heated gas flow direction, ensuring maximum linear heated gas travel and heat transfer. Low maintenance, durable refractory lined steel baffles are incorporated for heated gas flow direction between the second and third passes. Symmetrical tube design and layout provides equalized flow of heat into each tube from the furnace and successive gas passes, ensuring high efficiency. 1.2. Water Circulation All feedwater and water return connections enter the side of the vessel below the water line. By directing the make-up water below the water line of the boiler, the possibility of collapsing steam bubbles is eliminated allowing the boiler water to circulate naturally. 1.3. Tubes Boiler tubes are a minimum of 2-1/2” OD, with a wall thickness of 0.105”. Each tube is attached to the front and rear tube sheets through a rolling and beading process. High pressure boiler tubes are additionally seal welded at the entrance to the second pass. 1.4. Furnace The furnace or combustion chamber is centrally located within the pressure vessel. It consists of a single cylindrical tube strength welded to the front and rear tube sheets. It is symmetrical in layout, assuring a balance flow-circulating pattern under all load conditions. 1.5. Outer Casing (Jacket) The removable outer casing or jacket is fabricated of 22 gauge galvanealed steel panels supported by 2” thick fiberglass blanket insulation. This arrangement provides a skin temperature near ambient conditions. 1.6. Fireside Inspection Front and read doors (davited or hinged on 60 horsepower and larger) are furnished for tube inspection and cleaning of the second and third passes. An inner rear furnace access door is available for furnace inspection, eliminating the need to remove the burner. 1.7. Water Side Inspection For visual inspection of the water side internals and tube surfaces six 3” x 4” handhole inspection plates are provided. A 12” x 16” man hole is furnished for upper vessel inspection on boilers 80 horsepower and larger. 1.8. Flame Observation Port For visual inspection of the pilot and main flame ignition, there are two flame observation ports. One flame observation port is provided integral to the burner and one is located in the rear furnace access door. 1.9. Boiler Lifting Lugs Two lugs are provided to facilitate lifting and rigging the boiler into place. These lugs are located on the top centerline of the pressure vessel. 1.10. Boiler Base A structural steel welded base is provided upon which the pressure vessel is placed. The minimum height of the structural base is 4” and the boiler is attached to the base at four points (legs). A short base extension may be incorporated to provide mounting for a separate oil pump or oversize control panel. _______________________________________________________________________________________________________________________________________ Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com LATTNER BOILER COMPANY Page 4 Scotch Marine Boiler Operations Manual _______________________________________________________________________________________________________________________________________ 2. Boiler Connections 2.1. The following items are factory installed in accordance with the ASME Code: 2.1.1. Steam Connection The supply connection is located on the top centerline of the boiler and is either threaded or an ANSI flange design. The operating and design pressure of the boiler, in accordance with the ASME Code, determines the pressure rating of the flange. 2.1.2. Boiler Blowdown or Connection Drain Boilers under 80 horsepower have one threaded fitting on the bottom centerline at the rear of the pressure vessel. Boilers 80 horsepower and larger have two threaded fittings on the bottom centerline at the rear of the pressure vessel. 2.1.3. Surface Blow-Off A tapping is provided in the vessel near the normal water level line for connection to a manual or automatic surface contaminant removal system or metering valve. 2.1.4. Feedwater Make-Up A tapping is provided on each side of the pressure vessel for connection to the make-up and/or condensate return. 2.1.5. Exhaust Gas Vent (Stack) The connection for the stack or breaching is located at the rear on the top centerline of the boiler. This is a flanged connection, with the opening in accordance with the nominal dimension and rating sheets. A tapping is provided for a stack temperature probe or thermometer. 3. Boiler Trim The following are factory installed standard trim and control items. Trim items are supplied in accordance with the ASME Code. Controls
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